Method for finishing edges of glass sheets

ABSTRACT

A method for edge finishing glass sheets. Glass sheets are separated into desired sizes, after which the edges of the glass sheets are finished using first grinding wheels to grind the edges, followed by polishing wheels to round off the ground edges by contacting and moving the edges of the glass sheet against stationary rotating grinding and polishing wheels which are each oriented approximately parallel to the major surface of the glass sheet.

FIELD OF THE INVENTION

The invention relates to a method and apparatus for finishing the edgesof glass sheets, particularly sheets for use in flat panel displays.

BACKGROUND OF THE INVENTION

The manufacturing process of flat panel display substrates requiresspecific sized glass substrates capable of being processed in standardproduction equipment. The sizing techniques typically employ amechanical scoring and breaking process in which a diamond or carbidescoring wheel is dragged across the glass surface to mechanically scorethe glass sheet, after which the glass sheet is bent along this scoreline to break the glass sheet, thereby forming a break edge. Suchmechanical scoring and breaking techniques commonly result in lateralcracks about 100 to 150 microns long, which emanate from the score wheelcutting line. These lateral cracks decrease the strength of the glasssheet and are thus removed by grinding the sharp edges of the glasssheet. The sharp edges of the glass sheet are ground by a metal grindingwheel having a radiused groove on its outer periphery, with diamondparticles embedded in the radiused groove. By orienting the glass sheetagainst the radiused groove, and by moving the glass sheet against thisradiused groove and rotating the diamond wheel at a high RPM(revolutions per minute), a radius is literally ground into the edge ofthe glass sheet. However, such grinding methods involve removal of about100 to 200 microns or more of the glass edge. Consequently, themechanical scoring step followed with the diamond wheel grinding stepcreates an enormous amount of debris and particles.

In addition, in spite of repeated washing steps, particles generatedduring edge finishing continue to be a problem. For example, in somecases particle counts from the edges of glass sheets prior to shippingwere actually lower than subsequent particle counts taken aftershipping. This is because the grinding of the glass sheets resulted inchips, checks, and subsurface fractures along the edges of the groundsurfaces, all of which serve as receptacles for particles. Theseparticles subsequently would break loose at a later time, causingcontamination, scratches, and sometimes act as a break source in laterprocessing. Consequently, such ground surfaces are “active”, meaningsubject to expelling particles with environmental factors, such as,temperature and humidity. The present invention relates to methods forreducing these “lateral cracks” and “micro-checking” caused by grinding,thereby forming a glass sheet having edges that are more “inactive”.

Laser scoring techniques can greatly reduce lateral cracking caused byconventional mechanical scoring. Previously, such laser scoring methodswere thought to be too slow and not suitable for productionmanufacturing finishing lines. However, recent advances have potentiallyenabled the use of such methods in production glass finishingapplications. Laser scoring typically starts with a mechanical checkplaced at the edge of the glass. A laser with a shaped output beam isthen run over the check and along a path on the glass surface causing anexpansion on the glass surface, followed by a coolant quench to put thesurface in tension, thereby thermally propagating a crack across theglass in the path of travel of the laser. Such heating is a localizedsurface phenomenon. The coolant directed behind the laser causes acontrolled splitting. Stress equilibrium in the glass arrests the depthof the crack from going all the way through, thereby resulting in a“score-like” continuous crack, absent of lateral cracking. Such laserscoring techniques are described, for example, in U.S. Pat. Nos.5,622,540 and 5,776,220 which are hereby incorporated by reference.

Unfortunately, unbeveled edges formed by laser scoring are not asdurable as beveled edges, due to the sharp edges produced during thelaser scoring process. Thus, the sharp edges still have to be ground orpolished as described herein above. An alternative process has been togrind the edges with a polishing wheel made from a soft material, suchas, a polymer, in order to smooth out the flat sharp edges formed by thescoring process. However, the polishing process often gives rise to aphenomenon that is known in the industry as an “edge roll”, where duringthe finishing of an edge having a flat surface, the surface tends toroll over and form an associated radius.

In light of the foregoing, it is desirable to design a process to finishan edge of a glass sheet that curbs prospective chips, checks andsubsurface fractures along the edge. Also, it is desirable to provide aprocess that allows a smaller amount of glass removal and yet maintainthe edge quality. Furthermore, it is desirable to design a process thatincreases the speed of finishing an edge of a glass without degradingthe desired strength and edge quality attributes of the glass. Also, itis desirable to provide a technique that provides an edge withoutblended radiuses.

SUMMARY OF THE INVENTION

The present invention relates to a method for finishing the edges ofglass sheets comprising the steps of chamfering the top and bottom ofeach of the edges of the glass sheet to form chamfered planes whilereducing the overall width of each of the edges by not more than 35microns, and where the angle between each of the chamfered planes andthe adjacent major surface of the glass sheet is less than 40 degrees,preferably approximately 30 degrees. The method further comprisesrounding each edge formed by the intersection of each of the chamferedplanes and the original edge of the glass sheet. One such embodimentinvolves moving the edges of the glass sheet over at least one rotatinggrinding wheel having at least one v-shaped groove in the grindingsurface and one rotating polishing wheel having a flat polishingsurface, each of the grinding and polishing surfaces being oriented suchthat each of the grinding and polishing wheels are parallel to the majorplane of the glass sheet. In a preferred embodiment, the v-shaped groovein the grinding surface of the grinding wheel is embedded with diamondparticles, whereas the polishing surface of the polishing wheel issufficiently soft so that formation of a concave beveled edge isavoided. Also, a preferred embodiment, each of the grinding wheels havea surface speed that is greater than the surface speed of each of thepolishing wheels.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a process in accordance withthe present invention.

FIG. 2A illustrates a partial cross-sectional view illustrating thegrinding process illustrated in FIG. 1.

FIG. 2B illustrates a partial cross-sectional view of the grindingprocess illustrated in FIG. 1.

FIG. 2C illustrates a partial cross-sectional view of the grindingprocess illustrated in FIG. 1.

FIG. 3A illustrates a partial cross-sectional view of the polishingprocess illustrated in FIG. 1.

FIG. 3B illustrates a partial cross-sectional view of the polishingprocess illustrated in FIG. 1.

FIG. 3C illustrates a partial cross-sectional view of the polishingprocess illustrated in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention generally provides a method for grinding andpolishing the edges of a sheet of glass, in particular, a flat paneldisplay glass sheet. According to the present invention, the sheet ofglass is held in place by securing means and the sheet of glass isconveyed on a conveyer system as shown in FIG. 1. FIG. 1 illustrates apreferred embodiment of the invention in which a plurality of grindingwheels and polishing wheels are used to finish the edges of a glasssheet. FIG. 1 shows a glass sheet designated generally by referencenumeral 10 being conveyed on a conveyer system in the direction of arrow15 while at least one edge of the glass sheet 10 is being ground andpolished by the set of grinding wheels 20A and 20B and polishing wheels30A and 30B. The major surface 19 and 23 of each of the grinding wheels20A and 20B, respectively, and the major surface 33 and 29 of each ofthe polishing wheels 30A and 30B, respectively, are positioned parallelto the major surface 16 of the glass sheet 10. In the embodiment shownin FIG. 1, the grinding wheels 20A and 20B, each rotate in oppositedirections. Specifically, grinding wheel 20A rotates in acounterclockwise direction, whereas grinding wheel 20B rotates in aclockwise direction. Similarly, polishing wheels 30A and 30B each rotatein opposite directions. Specifically, polishing wheel 30A rotates in acounterclockwise direction, whereas polishing wheel 30B rotates in aclockwise direction.

As shown in FIG. 1, the grinding surface 21 of the grinding wheel 20Bcontacts one of the edges 14 of the glass sheet 10, whereas the grindingsurface 22 of the grinding wheel 20A contacts an opposite edge 12 of theglass sheet 10. Similarly, the polishing surface 32 of the polishingwheel 30A contacts the edge 12 of glass sheet 10, whereas the polishingsurface 31 of the polishing wheel 30B contacts the edge 14 of the glasssheet 10. In the preferred embodiment, each of the grinding wheels 20Aand 20B and each of the polishing wheels 30A and 30B rotatesimultaneously. Moreover, opposing edges 12 and 14 are simultaneouslyground and polished in the preferred embodiment. In particular, each ofthe edges 12 and 14 first contact the grinding surfaces 22 and 21 of thegrinding wheels 20A and 20B, respectively, and then the ground edgesnext contact the polishing surfaces 32 and 31 of each of the polishingwheels 30A and 30B, respectively. Also, as shown in FIG. 1, each of thegrinding wheels 20A and 20B are spaced apart from each of the polishingwheels 30A and 30B, with grinding wheel 20A and polishing wheel 30Abeing positioned proximate to each other on one edge 12 of the glasssheet 10, and with grinding wheel 30A and polishing wheel 30B beingpositioned proximate to each other on the other edge 14 of the glasssheet 10.

Furthermore, in the preferred embodiment, each of the grinding wheels20A and 20B and each of the polishing wheels 30A and 30B are stationary,whereas, the glass sheet 10 is moved in the direction of arrow 15, sothat each of the edges 12 and 14 are first ground and then polished.FIGS. 2A-2C show the details of one of the edges 12 being ground,whereas, FIGS. 3A-3C show details of the edge 12 being polished afterthe edge 12 has been ground. FIG. 2A shows a partial cross-sectionalview of the grinding surface 22 of the grinding wheel 20A. As shown, thegrinding surface 22 has at least one V-shaped groove 24 on the outerperiphery, where a radial line passing through the center of theV-shaped groove 24 forms an angle θ with the V-shaped groove 24. Theangle θ is in a preferred embodiment approximately between 15 and 40degrees, most preferably, approximately 30 degrees. Although FIG. 2Ashows only a single V-shaped groove 24, as shown in FIG. 1, the grindingwheels 20A and 20B each can have a plurality of V-shaped grooves 24, andin a preferred embodiment, each of the grinding wheels 20A and 20B havesix V-shaped grooves 24. As shown in FIG. 2A, the edge 12 of the glasssheet 10 is aligned with the V-shaped groove 24. Specifically, the edge12 has a flat region 12C located between a pair of corner regions 12Aand 12B respectively. As shown in FIG. 2B, the edge 12 is inserted intothe V-shaped groove 24 such that only the pair of corner regions 12A and12B contact the V-shaped groove 24, whereas, the middle portion of theflat region 12C does not contact the grinding surface 22 of the grindingwheel 20A. As the corner regions 12A and 12B are chamfered by theV-shaped groove 24, the pair of corner regions 12A and 12B aretransformed into a pair of ground beveled regions 12D and 12E,respectively, as shown in FIG. 2C. Also as shown in FIG. 2C, each of therounded beveled regions 12D and 12E form an angle θ with the top surface16A and the bottom surface 16B, respectively, of the glass sheet 10. Ina preferred embodiment, the angle θ is approximately between 15 and 40degrees, and most preferably, approximately 30 degrees. As shown in FIG.2C, the middle portion of the flat region 12C of the edge 12 remains thesame shape as before grinding, since this portion of the edge 12 is notcontacted by the grinding wheel 20A.

The ground edge 12 next contacts the polishing surface 32 of polishingwheel 30A, as shown in FIG. 3A. As shown in FIG. 3A, the polishingsurface 32 of polishing wheel 30A is substantially flat. Furthermore,the polishing surface 32 is sufficiently soft so that formation of aconcave beveled edge on the edge 12 is avoided. As shown in FIG. 3B, asthe ground edge 12 contacts the polishing surface 32 of the polishingwheel 30A, the polishing surface 32 becomes depressed in conformity withthe shape of the ground edge 12. In this manner, each of the sharpinterfaces that the ground beveled regions 12D and 12E form with theflat region 12C is substantially rounded, as represented by 12F and 12Gshown in FIG. 3C. The edge 14 of glass sheet 10 is rounded and polishedsimultaneously with edge 12 in a similar manner as described hereinabove, but instead with grinding wheel 20B and polishing wheel 30B.

In another aspect, the invention provides a method of finishing an edge12 of a glass sheet 10 having a thickness not greater than approximately3 mm. The method comprises the steps of chamfering the top surface 16Aand the bottom surface 16B of the edge 12 of the glass sheet 10 to formchamfered planes 12D and 12E while reducing the overall width of theedge 12 by not more than approximately 35 microns. Moreover, the angle θbetween each of the chamfered planes 12D and 12E and the adjacent majorsurfaces 16A and 16B of the glass sheet 10 is approximately less than 40degrees. The method further comprises the step of next rounding the edge12 formed by the intersection of each of the chamfered planes 12D and12E, and the original edge 12C of the glass sheet 10. The chamferingstep comprises contacting the top surface 16A and the bottom surface 16Bof the edge 12 of the glass sheet 10 with at least one rotating grindingwheel 20A that has a grinding surface 22 with at least one V-shapedgroove 24, where the grinding surface 22 is parallel to the majorsurface 16 of the glass sheet 10. Furthermore, the rounding stepcomprises contacting the top surface 16A and the bottom surface 16B ofthe edge 12 having chamfered planes 12D and 12E with at least onerotating polishing wheel 30A that has a polishing surface 32 that issufficiently soft so that formation of a concave chamfer on the edge 12is avoided. The angle θ formed by each of the chamfered planes 12D and12E with the adjacent top surface 16A and the bottom surface 16B of theglass sheet 10 is preferably approximately 30 degrees each.

Accordingly, the edge finishing process of the present invention removesnot more than approximately 35 microns from each edge of the glasssheet, which improves the strength of the glass sheet as well as theedge quality since less micro cracks are generated in the process.Moreover, the angle θ formed by each of the chamfered planes ispreferably approximately 30 degrees, which takes into account anylateral shifts of the glass sheet due to the grinding equipmentconveying inaccuracies.

The finishing method further comprises first conveying the glass sheet10 on a conveyer system that includes a plurality of wheels 18 (shown inFIG. 1). The conveyor system conveys the glass sheet 10 between each ofthe rotating grinding wheels 20A and 20B and each of the rotatingpolishing wheels 30A and 30B. Furthermore, the conveying step includessecuring glass sheet 10 onto the conveyer system by a set of belts 17that are partially shown in FIG. 1. The conveying step further includesfirst cutting the glass sheet 10 to size by forming at least a partialcrack in the glass sheet 10 along a desired line of separation, andleading the crack across the glass sheet 10 by localized heating by alaser, and moving the laser across the sheet to thereby lead the partialcrack and form a second partial crack in the desired line of separationand breaking the glass sheet 10 along the partial crack. Preferably, thegrinding wheels 20A and 20B rotate faster than the polishing wheels 30Aand 30B. In a preferred embodiment, each of the grinding wheels rotateat approximately 2,850 RPMs, whereas each of the polishing wheels rotateat approximately 2,400 RPMs. Moreover, the surface speed of each of thegrinding wheels 20A and 20B is greater than the surface speed of each ofthe polishing wheels 30A and 30B. Also, in a preferred embodiment, theglass sheet 10 is conveyed at a feed rate of approximately 4.5 to 6meters per minute. In a preferred embodiment, the diameter of each ofthe grinding wheels 20A and 20B is less than or equal to the diameter ofeach of the polishing wheels 30A and 30B.

In a preferred embodiment, the grinding wheels 20A and 20B employed inthe invention are metal bonded grinding wheels, each having six recessedgrooves, each of the grooves being embedded with diamond particles. Thediamond particles have a grit size in the range of approximately 400 to800, preferably about 400. Further, each of the grooves of the grindingwheels 20A and 20B employed in the invention are approximately 0.7 mmwide. Moreover, preferably, the grinding wheels 20A and 20B each have adiameter of 9.84 inches and a thickness of about one inch. The glasssheet 10 is conveyed at a feed rate of 4.5 to 6 meters per minute.Further, the surface speed of each of the grinding wheels 20A and 20B isapproximately 7,338 sfpm (surface feet per minute), whereas, the surfacespeed of each of the polishing wheels 30A and 30B is approximately 5,024sfpm. The polishing wheels 30A and 30B employed in the invention eachcomprise an abrasive media dispersed within a suitable carrier material,such, as a polymeric material. The abrasive media may be selected, forexample, from the group consisting of Al₂O₃, SiC, pumice, or garnetabrasive materials. Preferably, the particle size of the abrasive mediais equal to or finer than 220 grit, more preferably equal to or finerthan 180 grit. Examples of suitable abrasive polishing wheels of thissort are described, for example, in U.S. Pat. No. 5,273,558, thespecification of which is hereby incorporated by reference. Examples ofsuitable polymeric carrier materials are butyl rubber, silicone,polyurethane, natural rubber. One preferred family of polishing wheelsfor use in this particular embodiment are the XI-737 grinding wheelsavailable from Minnesota Mining and Manufacturing Company, St. Paul,Minn. Suitable polishing wheels may be obtained, for example, fromCratex Manufacturing Co., Inc., located at 7754 Arjons Drive, San Diego,Calif.; or The Norton Company, located in Worcester, Mass. In additionthe preferable diameter of each of the polishing wheels 30A and 30B isapproximately 8.0 inches and the thickness is about one inch.

Although the invention has been described in detail for the purpose ofillustration, it is understood that such detail is solely for thatpurpose and variations can be made therein by those skilled in the artwithout departing from the spirit and scope of the invention which isdefined by the following claims.

What is claimed is:
 1. A method of finishing an edge of a flat paneldisplay glass sheet, said edge having a flat region between a pair ofcorner regions, said method comprising the steps of: first contactingonly said pair of corner regions and not the middle portion of said flatregion of said edge with a rotating grinding wheel having a grindingsurface with at least one v-shaped groove, said grinding wheel beingparallel to the major surface of said glass sheet, wherein said pair ofcorner regions are transformed into a pair of ground beveled regions,each ground beveled region forming an angle θ with the adjacent majorsurface of said glass sheet, said angle θ being between approximately 15and 40 degrees; and next contacting said edge with a rotating polishingwheel having a substantially flat polishing surface on the outerperiphery, said polishing wheel being parallel to the major surface ofsaid glass sheet, said polishing surface being sufficiently soft so thatformation of a concave beveled edge is avoided, and wherein theinterface of each of said ground beveled regions with said flat regionis substantially rounded.
 2. The method of claim 1, further comprisingreducing the overall width of said edge by not more than 35 microns. 3.The method of claim 1, wherein said angle θ is approximately 30 degrees.4. The method of claim 1, further comprising simultaneously contactingonly a pair of corner regions of a second edge of said glass sheet andnot a middle portion a flat region of said second edge with a secondrotating grinding wheel having a grinding surface with at least onev-shaped groove, said grinding wheel being parallel to the major surfaceof said glass sheet, wherein said pair of corner regions are transformedinto a pair of ground beveled regions, each ground beveled regionforming an angle between approximately 15 and 40 degrees with theadjacent major surface of said glass sheet; and simultaneouslycontacting said second edge with a second rotating polishing wheelhaving a substantially flat polishing surface on the outer periphery,said polishing wheel being parallel to the major surface of said glasssheet, said polishing surface being sufficiently soft so that formationof a concave beveled edge is avoided, and wherein the interface of eachof said ground beveled regions with said flat region is substantiallyrounded.
 5. The method of claim 4, further comprising first conveyingsaid glass sheet on a conveyor system between each of said grindingwheels and each of said polishing wheels.
 6. The method of claim 5,wherein the rotational speed of each of said grinding wheels is greaterthan the rotational speed of each of said polishing wheels.
 7. Themethod of claim 6, wherein each of said grinding wheels has a grindingsurface with a plurality of v-shaped grooves.
 8. The method of claim 7,further comprising reducing the overall width of said edge by not morethan 35 microns.
 9. The method of claim 8, wherein the surface speed ofeach of said grinding wheels is greater than the surface speed of eachof said polishing wheels.